Method for making slab-faced and headed panels including corners or returns

ABSTRACT

There is disclosed a system for top pouring and vertical pouring of concrete or other construction material composition panels faced on one side or both sides with slabs (including full brick) wherein each panel includes a corner or a return at least partly faced with slabs. The casting is accomplished in a special, angulated casting box having the surfaces where slabs are to be located covered with vacuum plate inserts which are, in effect, combined resilient gaskets for preventing backing composition soilage of slab faces and means for holding slabs against the mold as the mold is moved or disposed to facilitate backing composition pouring.

United States Patent Kelsey [54] METHOD FOR MAKING SLAB-FACED AND BEADEDPANELS INCLUDING CORNERS OR RETURNS Inventor: Paul S. Kelsey, 715 SouthEast 8th St., Delray Beach, Fla. 33444 Filed: June 23, 1970 Appl. No.:49,148

[52] US. Cl. ..264/90, 264/256, 264/261,

264/277, 425/123, 425/453 Int. Cl. ..B32b 31/06. Field of Search..264/256, 261, 90'

25/1 B-D, 2, 41 L 12/1967 Johnson ..264/261 10/1958 Kastenbein ..264/261[l5] 3,694,533 [4 1 Sept. 26, 1972 2,427,604 9/1947 l-lolter ..264/308Primary Examiner-Robert F. White Assistant Examiner-Allen M. SokalAttorney-Cushman, Darby 8L Cushman 57 ABSTRACT There is disclosed asystem for top pouring and vertical pouring of concrete or otherconstruction material composition panels faced on one side or both sideswith slabs.(including full brick) wherein each panel includes a corneror a return at least partly faced with slabs. The casting isaccomplished in a special, angulated casting box having the surfaceswhere slabs are to be located covered with vacuum plate inserts whichare, in effect, combined resilient gaskets for preventing backingcomposition soilage of slab faces and means for holding slabs againstthe mold as the mold is moved or disposed to facilitate backingcomposition pouring.

\\\\\v n s b PATENTEDSEFZG I972 SHEET 2 0F 4 INVENTOR SE Y wig) B401 4PATENTED 3,694,533

sum u 0F 4 INVENTOR B904 Si K54 55 Y ATTORNEY;

BACKGROUND OF THE INVENTION In my co-pending U. S. Pat. application,Ser. No.49 l 52, filed June 23, 1970, the background of slabfaced panelcasting systems is disclosed in detail. Reference to the discussionthere is recommended, that application also discloses a panel castingsystem wherein a casting box having at least one vacuum line connectionthrough its floor is provided with a laminated insert plate whichincludes a resilient upper layer provided with one vacuum line openingfor each slab, and which incorporates conduits extending from theopenings to communication with the casting box floor. A placement gridhaving individual cells for receiving individual slabs is received inthe casting box on the insert plate upper layer. After a slab has beenplaced in each cell, a heavy seater is lowered onto the slabs to forcethem into sealing contact with the insert plate resilient upper layerand a vacuum is drawn through the casting box floor to hold the slabs sotightly against the insert plate resilient upper layer that the layerbulges up between adjacent slabs. The seater is removed with theassistance of removablelateral shims and a settable composition such asconcrete is poured into the casting box upon the slabs. The panels soformed'have slabs set therein with simulated semi-flush concave joints.A modified device for production of panels faced with slabs on bothsides is also disclosed.

- Corners and returns have consistently presented a problem for thosewho would wish to entirely industrialize the production of slab-facedmasonry walls. Even plain square or rectangular buildings have fourcorners, more complex perimetrical shapes often necessitated by buildinglot shapes or dictated by architectural considerations result in morecorners, some of which may be acute or oblique, rather than beingsimple, right angle corners.

A return results where an exposed window or door casing or the like isnot brought out flush with the straight-away wall portion it is includedin.

In normal hand laid brick structures, comers and exposed areas atwindows and doors give a most pleasing appearance because there is novertical line break off or demarcation line. The normal bond and itsjointwork follow around corners in a very pleasing manner one that notonly is pleasant to look at, but also one that indicates strengththrough the tie ins, or really, the lap ins achieved. In suchconstruction, the brick at the corners or returns each have a faceexposed on one wall and a head (i.e. an end) exposed on the other wall.

Sometimes, even in hand laid brick structures, bricklayers or those whodirect the work, will out of expediency or a willingness to accept lessthan what a craftsman would know to be right dispense with normal cornerbonding and instead produce a break at the corner characterized by astraight, vertical mortar .joint. Obviously, this is more thanaesthetically displeasi ng; it is structurally weaker since the twowalls are not tied together with intercalated brickwork. Similarexpediency leads builders to cover over brickwork with wooden millworkaround doors and windows where half or full returns would be moreaesthetically pleasing.

Most precast slab-faced panel system developers appear to have thrown uptheir hands on the question or how to produce normal corner bonding andthe appearance of well executed returns and reveals.

SUMIVIARY OF THE INVENTION There is disclosed a system for top pouringand vertical pouring of concrete or other construction materialcomposition panels faced on one side or both sides with slabs (includingfull brick) wherein each panel includes a corner or a return at leastpartly faced with slabs. The casting is accomplished in a special,angulated casting box having the surfaces where slabs are to be locatedcovered with vacuum plate inserts which are, in effect, combinedresilient gaskets for preventing backing composition soilage of slabfaces and meansfor holding slabs against the mold as the mold is movedor disposed to facilitate backing composition pouring.

By utilizing a tiltable combination, horizontal and vertical vacuumcasting table, that has special vacuum pads on both faces adjacent tothe comer line, and by making two spaced pours, one can duplicate thejointwork attained in normal hand laid brick corners. By incorporatingspecial vacuum inserts adjacent to end or side channels, one canduplicate the jointwork achieved with hand laid brick at door and windowopening returns as well as exposed indented joints sometimes effectivelyused between adjacent precast panels.

With the addition of a base plate and a splitting of the mold, a verypractical assembly is provided for casting all faced corner unitsvertically.

The principles of the invention will be further hereinafter discussedwith reference to the drawings wherein preferred embodiments are shown.The specifics illustrated in the drawings are intended to exemplify,rather than limit, aspects of the invention as defined in the claims.

BRIEF DESCRIPTION OF THE DRAWINGS In the Drawings:

FIG. 1 is a vertical, transverse sectional view of an angular castingbox lined with vacuum plate inserts, coursed slabs and after completionof the first of two pours of backing composition;

FIG. 2 is a left-half side elevation of the apparatus and partlycompleted product of FIG. 1;

FIG. 3 is a perspective view of a panel produced in the apparatus ofFIG. 1;

FIG. 3A is the projection of one end of the panel of FIG. 3 showing ahalf return;

FIG. 3B is the projection of another end of the panel of FIG. 3 showinga full return;

FIG. 4 is a horizontal, transverse sectional view of a modified angularcasting box designed to produce angular panels faced interiorly andexteriorly with slabs and shown lined with slabs and ready to havebacking composition poured thereinto;

FIG. 5 is a perspective view of a panel produced in the apparatus ofFIG. 4; and

FIGS. SA, 58, 5C and 5D are projections of respective surfaces of thepanel of FIG. 5.

DETAILED DESCRIPTION OF THE PRESENTLY PREFERRED EMBODIMENTS The termslabs" is used generically herein to include blocks of brick, thinbrick, slate and similar construction materials. Unless otherwiseindicated, dimensions are given by way of example.

The casting box of FIGS. 1 and 2 includes a first base plate 12 and asecond base plate 14 which adjoins the first at an included angle ofother than 180 degrees. In the instance depicted, the second base plateadjoins the first somewhat to the left of the right edge thereof. Achannel brace 16 is welded or otherwise secured to the protruding rightmarginal portion of the first base plate and to the outside of thesecond base plate. Several other channel braces 18 are welded orotherwise secured to the outsides of the first and second base plates toprovide support and resistance to buckling for the casting box baseplates.

During use of the FIGS. 1 and 2 embodiment of the casting box in ahorizontal position, it is necessary to rotate the casting box from acondition wherein the first base plate 12 is horizontal to anothercondition wherein the second base plate 14 is horizontal. To facilitatethis, the casting box 10 is provided with two axially spaced circularlycurved rockers 20, shown equipped with flat, circularly curved runners22 adapted to support the casting box 10 on a surface. The runnersextend sufiiciently in a circumferential extent to allow the casting boxto be moved between the two above-mentioned conditions.

The casting box 10 further includes two L-shaped end walls 24 ofopposite ends of the casting box. The two legs 26, 28 of each end wall24 respectively provide up-standing end walls for the two base plates 12and 14 and may be defined by channel members. The casting box sides areshown completed by a channel member 30 extending between the outer endsof the two walls 26 and another channel member 32 extending between theouter ends of the two walls 28. As shown, the inside surfaces of thewalls 26, 28, 30 and 32 are all flat.

Each of the walls 30 and 32 and the base plates 12 and 14 have openings34 therethrough for application of vacuum to hold slabs against theinterior of the mold. Suitable vacuum lines 36 connected to the openings34 exteriorly of the casting box are communicated to a source ofsuction, e.g. a vacuum pump. Shut off valves 38 are interposed in thevacuum lines 36 in each branch to permit isolation of communication ofsuction to the several openings 34. The interior of the casting box 10is shown provided with vacuum plate inserts 40A, 40B, 40C and 40Drespectively having the first base plate 12, the second base plate 14,the sidewall 30 and the sidewall 32.

Each of the vacuum plate inserts (collectively referred to by thenumeral 40) includes an outer layer 42 of closed cell foam rubber orlike resilient material, an intermediate layer of stiffer material suchas plywood or steel plate 44 and an inner liner 46 of closed cell foamrubber or like resilient material. The layers 42, 44 and 46 are providedwith interconnecting openings 48 positioned to communicate the vacuumopenings 34 with each site on the inner face 50 where a slab is to beheld positioned by vacuum. The preferred shape of the openings 48 is asdepicted and explained in my above-mentioned copending U. S. Pat.application.

The layers of the vacuum plate inserts are secured to one another, forinstance, with suitable adhesive.

Fillers 52 of square cross section are secured in the three corners ofthe casting box where edges of two vacuum plate inserts 40 adjoin oneanother so that one insert 40 does not have to slip behind an edge ofanother and so that the comers are occupied.

As depicted, the vacuum plate insert 40D extends only part way up thewall 30 (i.e. the length of a brick head). The remainder of the wall 30is covered by a spacer 54 whose thickness equals that of the vacuumplate insert when the latter is compressed.

The casting box 10 is prepared for casting by cleaning and oiling itsinterior metal surfaces, installing the vacuum plate inserts as shown.If necessary, the vacuum plate inserts may be maintained in place bymeans such as removable pins 56 projecting inwardly through the endwalls 24 into slots in the corresponding edges of the intermediatelayers 44 of the vacuum plate inserts. The slots are slightly elongatedin such sense as to maintain the respective inner liner 46 abutting therespective casting box surface when the vacuum is off, but allow therespective vacuum plate insert to compress toward the respective castingbox surface when the vacuum is turned on.

Next the casting box containing the emplaced vacuum plate inserts islined with slabs S, each slab covering an outlet of an opening 48. Bypreference, as shown each slab S which has a head H against one vacuumplate insert and a face F against another vacuum plate insert covers anoutlet of an opening 48 on each respective vacuum plate insert.Placement grids are preferably used to locate the slabs as described inmy above-mentioned copending application. When all of the slabs Scovering openings 48, 34 in one branch of the lines 36 are properlylocated and pressed against their respective vacuum plate inserts, thecorresponding shut off valve 38 is opened and the slabs seated againstthe respective vacuum plate insert. This results in gasketing of theinsert against the casting box, gasketing of the insert against theslabs which cover it, some resilient compression of the linings 42 and46 of the vacuum plate insert and some bulging of the liner 46 upbetween adjacent slabs.

Openings 34 covered by spacers 54 may have their respective shut-offvalves 38 left closed.

When all of the slabs have been positioned in this manner and thecasting box positioned as shown in FIG. 1, fluid, settable backingcomposition, such as mortar M may be poured into the casting box andscreeded level with the upper edges of the walls 30 and 26. After thiscomposition has set sufficiently, the casting box 10 is rocked about ahorizontal axis on the rockers 20, 22 until the vacuum plate insert 408is disposed horizontally. Then a second quantum of backing compositionis introduced into the casting box and screeded level with the upperedges of the walls 32 and 28. It should be noted that the bulging of theliner 46 between adjacent slabs causes a desirable semi-flush concavejoint simulation to be created between adjacent slab faces. When thebacking composition has set, the vacuum is turned off by closing thevalves 38 or their master 58, the casting box is partly disassembled,for instance by removing one or more of the sidewalls 30, 32 and thecompleted panel P is removed from the casting box. As shown in FIGS. 3,3A and 3B, the exemplary panel P formed in the casting box has twooutside surfaces faced with brick slabs S in what appears to be normalcoursing; a half return is provided on the wall edge depicted in FIG. 3Aand a full return is provided on the wall edge depicted in FIG. 3B. Theincluded angle of the corner panel P depicted is 90 degrees and the twointerior surfaces of the panel are plain and unfaced in the example.

The use of an open topped mold on rockers maximizes access to theinterior of the casting box and makes less disassembly necessary forpermitting removal of completed panels.

I However, it should be apparent that the mold shown horizontally inFIG. 1 couldbe used vertically provided most end wall 24 would have tobe provided with an opening or preferably eliminated, to permit pouringof backing composition B into the casting box. Very succinctly, thechanges mentioned in the foregoing paragraph and a few furthermodifications constitute what is depicted in FIG. 4.

In the embodiment of FIG. 4 which is capable of producing the panel P2of FIGS. 5 and SA-SD, the changes just outlined are supplemented byprovisions for greater disassembly of the casting box, of a strongerbottom wall and of added vacuum plate inserts disposed against the twoadded aforementioned walls.

The corresponding elements between the embodiments of FIGS. 1 and 4 havebeen given the same numerals. The differences apparent in the F IG. 4'embodiment are as follows;

l. The casting box is sitting upright and the viewer is lookingdownwardly into it. Thus, what would be an upper end wall has beeneliminated inorder to create an open top mold.

2. The opposite, lower end wall 24 has been expanded from L-shape by theinclusion of a strengthening triangular web 66.

3. The extra walls 68, 70 have been provided to complete the inner sidesof the mold as outlined above and these have been lined with vacuumplate inserts 40E and 40F. The walls 30 and 32 have each been dividedinto two portions 30A, 30B and 32A, 32B and their covering vacuum plateinserts have likewise each been divided into two portions 40C 1, 40C2and 40Dl, 40D2.

This permits ease of assembly and disassembly of the mold, since, inassembly, the walls 30A, 12, 14 and 32A may be bolted to one another andto the bottom base plate 24 as shown at 72, as a first assembly, and thewalls 30B, 68, 70 and 328 may be secured to one another as shown, as asecond assembly. After the two assemblies have been cleaned, oiled,vacuum plate inserts respectively installed, slabs S emplaced, seatedand vacuum applied to maintain them in place through the lines 36, thetwo assemblies may be bolted together at 74.

As a review, it should be noted that the mold of the preferredembodiment of FIG. 4 may contain eight vacuum plate inserts: 40A, 40B,40C], 40C2, 40Dl, 40D2, 40B and 40F. Actually, in the embodimentdepicted, the insert 40D2 is a spacer substantially identical to thespacer 56 of FIG. 1 in order to produce the special wall ending depictedin FIG. 5A.

The mold is depicted in FIG. 4 with all of the slabs S in place, vacuumcommunicated to all of the vacuum plate inserts and ready for acceptanceof a pour of backing composition.

To back track slightly, a use of the mold as depicted in FIG. 4 toproduce a mortar backed panel faced on all sides with brick or brickslabs will now be discussed in detail in order to more clearly exemplifycertain aspects of the invention.

In the following discussion, the individual casting box walls or pairsof walls having respective vacuum plate inserts bolted to them will bereferred to as sub assemblies in accordance with the following schedule:

It is assumed that the sub assemblies and the bottom plate which make upthe vertical pour casting box of FIG. 4 have been individually cleanedand oiled.

Step I A. Rest sub assembly A on horses, (not shown), of suitable heightso that its securely bolted in place vacuum plate inserts are face up. T

B. Bolt in place beside the vacuum plate inserts two temporary 2 inchesX 2 A inches X A inch angle irons which are to both complement and helphold in correct position their respective slab locating placement grids,(not shown, but of the same general design as are fully discussed in myaforementioned co-pending U. S. Pat. application).

C. Position the locating grid for vacuum plate insert D. Fill thatlocating grid with required 1 inch thick half slabs S1, special 1 inchthick slabs 8 1'. inches long S2, half corner split brick S3 or fullcorner split brick S4 as required. Each slab or comer split brick is tobe individually hand seated and individually vacuum gripped.

E. Remove the locating grid from vacuum plate insert 40F and itscomplementary supporting angle iron.

F. Duplicate above procedures with vacuum plate insert 40E.

STEP 2 A. Position sub assembly B and vacuum grip to it adjacent halfand full corner split brick headers as shown in FIG. 4.

B. Bolt sub assembly B to sub assembly A.

C. Proceed in the same manner with sub assembly C.

STEP 3 A. Bolt bottom plate 24 to sub assembly D.

B. Position sub assembly D in a horizontal position and so that thesurface to which vacuum plate insert 40B is secured is horizontal andvacuum plate insert A is secured to that main surface which is vertical.

C. Bolt in place two temporary 2 x inches X 2 k inches X '74; inch angleirons, which are to both complement and help hold in position theirrespective locating grids.

D. Position a locating grid upon vacuum plate insert E. Fill thelocating grid with appropriate 1 inch thick half S1 or full slabs S4 andhalf S3 or full S4 comer split brick, hand setting and individuallyvacuum gripping each one. Where a split comer brick has two faces incontact with vacuum pad inserts, the vacuum is to be applied to theheader face H first and to the stretcher face F last.

F. Remove the locating grid and its complementary supporting angle iron.

STEP 4 A. Rotate main rocker casting box frame (i.e. sub assembly B) 90degrees, thus bringing vacuum plate insert 40A to a horizontal positionand vacuum plate insert 403 to a vertical position.

B. Proceed to place a locating grid on vacuum plate insert 40A in itscorrect position and then place in its cells the appropriate slabs orbrick as was done on vacuum plate insert 40B.

C. Seat the slabs and brick and apply vacuum.

D. Remove the supporting angle iron and locating grid from vacuum plateinsert 40A.

STEP 5 A. Position sub assembly E and vacuum grip adjacent half and fullcorner split brick headers to it.

B. Bolt sub assembly E down to sub assembly D.

C. Proceed in the same manner with sub assembly F.

STEP 6 A. Lower sub assembly A with itscomplement of vacuum grippedbrick and brick slabs and installed sub assemblies B and C into positiononto sub assembly D and its complement of brick and brick slabs andattached sub assemblies E and F. Coaxial bolt holes in adjacent subassemblies E and B as well as in adjacent sub assemblies C and F allowthese two major assemblies to be bolted together. Like coaxial matchingbolt holes at this time allow the bolting of sub assemblies F, C, B andE directly to the bottom base plate 24.

STEP 7 A. While continuing to maintain vacuum, the fully assembled andcompletely faced casting box is lifted into a vertical position on itsbottom plate, i.e. to the position shown in FIG. 4.

STEP 8 A. Pour the casting box full of fairly soft consistancy mortar orother fluid, settable backing composition at a slow even rate whilemaintaining moderate internal vibration.

B. Screed off top and imbed heavy duty lifting core with attachedreinforcing rods into casting at its approximate geometric center.

C. Keep vacuum on until mortar is quite hard and form removal is inprocess.

STEP 9 A. Release vacuum from all branches of line 36.

B. Remove bolts holding sub assembly A to sub assemblies B and C.

C. Lift off sub assembly A.

D. Remove sub assemblies B and E from sub assembly D and base plate 24after removing necessary bolts.

E. Remove, in the same manner, sub assemblies C and F from sub assemblyD and base plate 24.

F. At this point with some types of facings the completed comer unit(the panel of FIG. 5) can be safely freed from the remaining casting boxand removed to storage. However, certain facing materials may not permitsafe removal at this stage without the introduction of high pressure airinto that part of the vacuum piping which still leads to areas wherethere is still contact between facing units and the vacuum plate insertssurfaces. There may be an individual or a few facings that will notbreak loose even with the air treatment. In such cases, it may benecessary to further dismantle the casting box. The whole assemblybacking up vacuum plate insert 408 can be removed by removing a few morebolts. Likewise even the base plate can be detached. With contact onlyleft between the casting and vacuum plate insert 40A, there can be nofurther removal difficulty. The built-in disassembly provisions justdescribed are provided to make it possible to safely remove castingsregardless of how tough or penetrating their facings may be.

It should be apparent that the casting boxes have been shown havingright angle comers since right angle cornered panels are obviously inmost demand; casting boxes having different included angles do notdiffer in principle from the two just discussed. It should also beappreciated that many other kinds and arrangements of facings can beprovided than those depicted and that by substituting spacers 54 for anyvacuum plate inserts, the desired panel surfaces or parts thereof can beleft unfaced.

It should now be apparent that the slab-faced and headed panelsincluding comers or returns as described herein above possesses each ofthe attributes set forth in the specification under the heading Summaryof the Invention hereinbefore. Because the slab-faced and headed panelsincluding corners or returns of the invention can be modified to someextent without departing from the principles of the invention as theyhave been outlined and explained in this specification, the presentinvention should be understood as encompassing all such modifications asare within the spirit and scope of the following claims.

What is claimed is:

1. A process for manufacturing slab-faced panels which include comers,comprising:

a. disposing two generally planar surfaces to meet at an inside cornerhaving an included angle of less than b. completely bordering said twosurfaces, except longitudinally along the comer, with upstandingconfining surfaces extending generally normally to the respectivelybordered surfaces;

c. providing a covering of resilient gasketing material on said twosurfaces;

(1. temporarily disposing a reticulated placement grid, having aplurality of slab-receiving cells, flatwise, upon each of said coveredsurfaces;

e. inserting a slab front-face-forward in each cell; f. pushing eachslab, upon the rear face thereof,

ing material that it bulges up perimetrically of each of the slabs; thenh. terminating the exertion of said greater-than-atmospheric pressureforce;

i. removing the reticulated placement grid from the vicinity of theslabs;

j. disposing two generally planar covering surfaces to meet at anoutside corner having an included angle generally equal to the angle ofstep (a) and securing the. covering surfaces in such dispositionperipherally upon borders of the upstanding confining surfaces, distallyof said two surfaces of step (a) that the covering surfaces generallyparallel the respective ones of said two surfaces of step (a);

k. introducing a hardenable fluid backing composition onto the array ofslabs sealed to the horizontal one of said two surfaces in asufficiently fluid condition and in sufficientquantity that thecomposition substantially fills the free space unoccupied by said slabsupon the resilient gasketing material and slabs disposed on one of saidtwo surfaces and unoccupied by said slabs upon the resilient gasketingmaterial and slabs disposed on the other one of said two surfaces,

covering surface;

I. allowing the hardenable fluid backing composition to harden;

m. terminating said drawing of vacuum; and

n. removing the slab faced corner panel thus created from the vicinityof said two surfaces, resilient gasketing material, upstanding confiningsurfaces, and covering surfaces.

2. The process of claim 1 comprising the additional steps of:

' d. defining an array of slab-receiving cells on that coveredupstanding confining surface as a progression of the cells temporarilydefined on the respectively adjacent of said covered two surfaces;

e. inserting a slab front-face-forward in each cell of said array onthat covered upstanding confining surface;

I f. conducting step (f) in respect to the slabs of (e');

g. conducting step (g) in respect to the gasketing material of step (c)and the slabs of step (e),

up to the level of the respective 10 prior to conducting steps (h)through (n) to produce a slab faced comer panel having at least one atleast partial return.

3. The process of claim 2 comprising the additional steps of:

c". providing a covering of resilient gasketing material on at least oneof said covering surfaces; cl". defining an array of slab-receivingcells on that covered covering surface;

e". inserting a slab front-face-forward in each cell of said array onthat covered covering surface;

f' conducting step (f) in respect to the slabs of step g". conductingstep (g) in respect to the gasketing material of step (c") and the slabsof step (e"), prior to conducting steps (h) through (n), to produce aslab faced corner panel having at least the inner and outer surfacesthereof extending from the inside and outside corners thereof faced withslabs.

4. The process of claim 3 wherein at least some of said slabs arearrayed in a simulation of staggered courses and wherein at least someof said slabs are L- shaped, so that conducting each of steps (e), (e')and (e") includes inserting at least one L-shaped slab in an L-shapedcellhaving front faces simultaneously on two of said covered surfaces,and so that conducting each of steps (f), (f') and (f") includes pushingeach such L- shaped slab upon both rear faces thereof, against theresilient gasketing material on the two respective ones of said coveredsurfaces.

5. The process of claim 1 comprising the additional steps of:

c. providing a covering of resilient gasketing material on at least oneof said covering surfaces; d. defining an array of slab-receiving cellson that covered covering surface;

e'. inserting a slab front-face-forward in each cell of said array onthat covered covering surface;

f'. conducting step (f) in respect to the slabs of step g. conductingstep (g) in respect to the gasketing materialof step (c) and the slabsof step (e), prior to conducting steps (b) through (11), to produce aslab faced corner panel having at least the inner and outer surfacesthereof extending from the inside and outside comers thereof faced withslabs.

6. A process for manufacturing slab-faced panels which include corners,comprising:

a. disposing two generally planar surfaces to meet at a comer having anincluded angle of less than b. completely bordering said two surfaces,except longitudinally along the corner, with upstanding confiningsurfaces extending generally normally to the respectively borderedsurfaces;

c. providing a covering of resilient gasketing material on said twosurfaces;

d. temporarily disposing a reticulated placement grid, having aplurality of slab-receiving cells, flatwise, upon each of said coveredsurfaces;

e. inserting a slab front-face-forward in each cell;

f. pushing each slab, upon the rear face thereof,

against the resilient gasketing material with sufficient force greaterthan atmospheric pressure to seal the front face of each slab to theresilient gasketing material; while g. drawing a vacuum through theresilient gasketing material generally centrally of each cell tomaintain the slabs in contact with the resilient gasketing material andto so resiliently compress the gasketing material that it bulges upperimetrically of each of the slabs; then h. terminating the exertion ofsaid greater-than-atmospheric pressure force;

i. removing the reticulated placement grid from the vicinity of theslabs;

j. disposing said two surfaces so that one of them is generallyhorizontal and the other projects upwardly;

k. introducing a hardenable fluid backing composition onto the array ofslabs sealed to the horizontal one of said two surfaces in asufficiently fluid condition and in sufficient quantity that thecomposition substantially fills the free space unoccupied by said slabsupon the resilient gasketing material and slabs disposed on thehorizontal one of said two surfaces and unoccupied by said slabs uponthe resilient gasketing material and slabs disposed on the upwardlyprojecting other one of said two surfaces, up to the level of the upperextent of the upstanding conflning surfaces bordering the horizontal oneof said two surfaces;

1. after said hardenable fluid backing composition has hardenedsufficiently to retain the shape and disposition thereof if moved to anupright disposition, redisposing said two surfaces so that the other oneof them is generally horizontal and said one of them projects upwardly;

m. introducing an additional quantity of said hardenable fluid backingcomposition onto the array of slabs sealed to the horizontal other oneof said two surfaces, beside and in intimate contact with saidsufficiently hardened hardenable fluid backing composition, in asufiiciently fluid condition and in sufficient quantity that theadditional quantity of said composition substantially fills the freespace unoccupied by said slabs, and unoccupied by said sufficientlyhardened hardenable fluid backing composition, upon the resilientgasketing material and slabs disposed on the horizontal other one ofsaid two surfaces, up to the level of the upper extent of the upstandingconfining surfaces bordering the horizontal other one of said twosurfaces;

n. allowing the hardenable fluid backing composition to harden;

o. terminating said drawing of vacuum; and

p. removing the slab faced corner panel thus created, from the vicinityof said two surfaces, resilient gasketing material and upstandingconfining surfaces.

1. A process for manufacturing slab-faced panels which include corners,comprising: a. disposing two generally planar surfaces to meet at aninside corner having an included angle of less than 180* ; b. completelybordering said two surfaces, except longitudinally along the corner,with upstanding confining surfaces extending generally normally to therespectively bordered surfaces; c. providing a covering of resilientgasketing material on said two surfaces; d. temporarily disposing areticulated placement grid, having a plurality of slab-receiving cells,flatwise, upon each of said covered surfaces; e. inserting a slabfront-face-forward in each cell; f. pushing each slab, upon the rearface thereof, against the resilient gasketing material with sufficientforce greater than atmospheric pressure to seal the front face of eachslab to the resilient gasketing material; while g. drawing a vacuumthrough the resilient gasketing material generally centrally of eachcell to maintain the slabs in contact with the resilient gasketingmaterial and to so resiliently compress the gasketing material that itbulges up perimetrically of each of the slabs; then h. terminating theexertion of said greater-than-atmospheric pressure force; i. removingthe reticulated placement grid from the vicinity of the slabs; j.disposing two generally planar covering surfaces to meet at an outsidecorner having an included angle generally equal to the angle of step (a)and securing the covering surfaces in such disposition peripherally uponborders of the upstanding confining surfaces, distally of said twosurfaces of step (a) that the covering surfaces generally parallel therespective ones of said two surfaces of step (a); k. introducing ahardenable fluid backing composition onto the array of slabs sealed tothe horizontal one of said two surfaces in a sufficiently fluidcondition and in sufficient quantity that the composition substantiallyfills the free space unoccupied by said slabs upon the resilientgasketing material and slabs disposed on one of said two surfaces andunoccupied by said slabs upon the resilient gasketing material and slabsdisposed on tHe other one of said two surfaces, up to the level of therespective covering surface; l. allowing the hardenable fluid backingcomposition to harden; m. terminating said drawing of vacuum; and n.removing the slab faced corner panel thus created from the vicinity ofsaid two surfaces, resilient gasketing material, upstanding confiningsurfaces, and covering surfaces.
 2. The process of claim 1 comprisingthe additional steps of: c''. providing a covering of resilientgasketing material on at least one of said upstanding confiningsurfaces; d''. defining an array of slab-receiving cells on that coveredupstanding confining surface as a progression of the cells temporarilydefined on the respectively adjacent of said covered two surfaces; e''.inserting a slab front-face-forward in each cell of said array on thatcovered upstanding confining surface; f''. conducting step (f) inrespect to the slabs of (e''); g''. conducting step (g) in respect tothe gasketing material of step (c'') and the slabs of step (e''), priorto conducting steps (h) through (n) to produce a slab faced corner panelhaving at least one at least partial return.
 3. The process of claim 2comprising the additional steps of: c''''. providing a covering ofresilient gasketing material on at least one of said covering surfaces;d''''. defining an array of slab-receiving cells on that coveredcovering surface; e''''. inserting a slab front-face-forward in eachcell of said array on that covered covering surface; f''''. conductingstep (f) in respect to the slabs of step (e''''); g''''. conducting step(g) in respect to the gasketing material of step (c'''') and the slabsof step (e''''), prior to conducting steps (h) through (n), to produce aslab faced corner panel having at least the inner and outer surfacesthereof extending from the inside and outside corners thereof faced withslabs.
 4. The process of claim 3 wherein at least some of said slabs arearrayed in a simulation of staggered courses and wherein at least someof said slabs are L-shaped, so that conducting each of steps (e), (e'')and (e'''') includes inserting at least one L-shaped slab in an L-shapedcell having front faces simultaneously on two of said covered surfaces,and so that conducting each of steps (f), (f'') and (f'''') includespushing each such L-shaped slab upon both rear faces thereof, againstthe resilient gasketing material on the two respective ones of saidcovered surfaces.
 5. The process of claim 1 comprising the additionalsteps of: c''. providing a covering of resilient gasketing material onat least one of said covering surfaces; d''. defining an array ofslab-receiving cells on that covered covering surface; e''. inserting aslab front-face-forward in each cell of said array on that coveredcovering surface; f''. conducting step (f) in respect to the slabs ofstep (e''); g''. conducting step (g) in respect to the gasketingmaterial of step (c'') and the slabs of step (e''), prior to conductingsteps (h) through (n), to produce a slab faced corner panel having atleast the inner and outer surfaces thereof extending from the inside andoutside corners thereof faced with slabs.
 6. A process for manufacturingslab-faced panels which include corners, comprising: a. disposing twogenerally planar surfaces to meet at a corner having an included angleof less than 180* ; b. completely bordering said two surfaces, exceptlongitudinally along the corner, with upstanding confining surfacesextending generally normally to the respectively bordered surfaces; c.providing a covering of resilient gasketing material on said twosurfaces; d. temporarily disposing a reticulated placement grid, havinga plurality of slab-receiving cells, flatwise, upon each of said coveredsurfaces; e. inserting a slab front-face-forward in each cell; f.pushing each slab, upon the rear Face thereof, against the resilientgasketing material with sufficient force greater than atmosphericpressure to seal the front face of each slab to the resilient gasketingmaterial; while g. drawing a vacuum through the resilient gasketingmaterial generally centrally of each cell to maintain the slabs incontact with the resilient gasketing material and to so resilientlycompress the gasketing material that it bulges up perimetrically of eachof the slabs; then h. terminating the exertion of saidgreater-than-atmospheric pressure force; i. removing the reticulatedplacement grid from the vicinity of the slabs; j. disposing said twosurfaces so that one of them is generally horizontal and the otherprojects upwardly; k. introducing a hardenable fluid backing compositiononto the array of slabs sealed to the horizontal one of said twosurfaces in a sufficiently fluid condition and in sufficient quantitythat the composition substantially fills the free space unoccupied bysaid slabs upon the resilient gasketing material and slabs disposed onthe horizontal one of said two surfaces and unoccupied by said slabsupon the resilient gasketing material and slabs disposed on the upwardlyprojecting other one of said two surfaces, up to the level of the upperextent of the upstanding confining surfaces bordering the horizontal oneof said two surfaces; l. after said hardenable fluid backing compositionhas hardened sufficiently to retain the shape and disposition thereof ifmoved to an upright disposition, redisposing said two surfaces so thatthe other one of them is generally horizontal and said one of themprojects upwardly; m. introducing an additional quantity of saidhardenable fluid backing composition onto the array of slabs sealed tothe horizontal other one of said two surfaces, beside and in intimatecontact with said sufficiently hardened hardenable fluid backingcomposition, in a sufficiently fluid condition and in sufficientquantity that the additional quantity of said composition substantiallyfills the free space unoccupied by said slabs, and unoccupied by saidsufficiently hardened hardenable fluid backing composition, upon theresilient gasketing material and slabs disposed on the horizontal otherone of said two surfaces, up to the level of the upper extent of theupstanding confining surfaces bordering the horizontal other one of saidtwo surfaces; n. allowing the hardenable fluid backing composition toharden; o. terminating said drawing of vacuum; and p. removing the slabfaced corner panel thus created, from the vicinity of said two surfaces,resilient gasketing material and upstanding confining surfaces.